Converted log structural products and method

ABSTRACT

Converted log structural products are produced from conventionally unusable or marginally useful sections of logs transversely cut into suitable lengths and then cut longitudinally by perpendicular cuts into log parts of either right-angled sector or right triangle cross-section. Four log parts matching in size and shape, and positioned so that their right angles form the corners of a rectangle, are assembled into a converted log, the interior space between the four log parts being filled selectively with braces, supports, insulation, concrete for various applications.

BACKGROUND OF THE INVENTION

This application is related to my U.S. Pat. No. 5,115,609, issued May26, 1992, .Iadd.is a reissue application of my U.S. Pat. No. 5,299,400,issued Apr. 5, 1994, .Iaddend.and covers subject matter not disclosed orclaimed in the .Iadd.first .Iaddend.issued patent.

The .Iadd.first .Iaddend.issued patent disclosed a method to produceuseful lumber products, superior in strength, lightness, handling andcosts from trees of 8-10 years' growth as compared to trees aged 35years and more used for conventional lumber. FIGS. 1 and 2 of theaccompanying drawings illustrate the basic concepts of the priorinvention. FIG. 1 shows an end view of trimmed debarked log 10, to beconverted by dividing it into quarter-segments 12 by two diametricallongitudinal cuts at right angles to each other along planes 14 and 16.Trimming cuts along planes 18, 18' parallel to plane 14 may be performedif desired; obviously, corresponding cuts parallel to plane 16 can bemade. As FIG. 2 illustrates, when quarter-segments 12 are rotated sothat perpendicularly cut surfaces 20 and 22 face outwardly, segments 12can be oriented to form a peripheral rectangular cross-section and canbe secured together in this position into a length of the converted logproduct.

It is the principal object of this invention to expand the concepts ofthe prior art to include the conversion and enhancement of portions oflarger logs from older trees, especially those portions nowconventionally considered unfit for structural lumber, into strong,light, smooth, easily handled and above all inexpensive structurallumber.

SUMMARY OF THE INVENTION

In the conventional sawing of timber into structural lumber, the roundedportions near the outer circumference of the logs must be discarded;similarly, in logs being cut into thin sheets as laminations for plywoodmanufacture, the logs being continually rotated during cutting. The woodveneers become unusable when the diameter of the residual log core hasbeen reduced to the range of 6-7 inches, the core then being relegatedto use as firewood or pulp. Using these substantially rejected logportions, the present invention advantageously provides buildingmaterials of highly desirable characteristics. Additionally, a length oflumber previously made square can be increased in cross-sectional sizeby mere than 40% without sacrificing strength and with improvedinsulative and handling by the method disclosed herein.

The present invention uses portions of larger logs which have beentrimmed and cut transversely into selected lengths (normally 8 feet).Two longitudinal cuts at right angles to each other provide lengths oflog parts, three-sided in cross-section, whether right-angled sectorswith the third side contoured by the curvature of the outer logcircumference, or right triangles when cut from square logs. In allcases, four equally sized and shaped log parts are assembled byorienting them in reverse of their original position before cutting,with their prior outside surfaces now pointing inwardly, so that theouter peripheral edges of the four log parts as now arranged form arectangle. The log parts may now be secured together, interiorly bracedif desired and the interior space existing between the assembled logparts filled with suitable insulating material or the like.

All the preferred embodiments of the converted log structural products,and the method of producing them, will now be fully described inconnection with the accompanying illustrative, but not limiting,drawings, wherein:

SHORT FIGURE DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic end view of a small log as converted by the priorart method;

FIG. 2 is a perspective partial exploded end view of the prior art logof FIG. 1 in its cut and reoriented arrangement prior to final assembly;

FIG. 3 is a schematic end view of a larger log, showing a plan fordividing the log into portions for use as conventional lumber as well asfour equal symmetrical sectors for use in the practice of thisinvention;

FIG. 4 is a cross-sectional view of the four equal sectors of FIG. 3rearranged, combined and assembled with foam plastic insulation to forma converted log preferred embodiment of this invention;

FIG. 5 is a schematic end view of a larger log, demonstrating how, afterthe outer portion of the log has been cut into layers for laminationinto plywood, all in a conventional manner, the central inner core ofthe log may be longitudinally cut into log portions for use in thepractice of this invention;

FIG. 6 is a cross-sectional view of the log core parts of FIG. 5,rearranged and assembled into another preferred embodiment of aconverted log, its interior space being filled with reinforced concrete;

FIG. 7 is a perspective partial end view of four log parts cut andreoriented in accordance with this invention, the log parts being of twodifferent wood species;

FIG. 8 is a schematic end view of a length of timber squared incross-section, showing a plan for dividing it into portions for assemblyas another preferred embodiment;

FIG. 9 is a cross-sectional view of the log parts of FIG. 8, rearrangedand assembled into a preferred embodiment, its interior space beingfilled with a softer wood shaped to mate with and fill the interiorspace;

FIG. 10 is a perspective end view of another converted log embodiment,which uses the log parts of FIG. 8 and employs braces and wedge supportsfor strengthening and sealing the converted log product;

FIG. 11 is a cross-sectional view of the converted log embodiment ofFIG. 10, its interior space being filled with treated insulative woodshavings or chips;

FIG. 12 is a schematic partial end view of a larger log showing analternative plan for dividing the log into portions for conventionallumber use and four right-angled asymmetrical sectors for use in thepractice of this invention;

FIG. 13 is a perspective view of still another converted log embodimentusing the asymmetric log sectors of FIG. 12; and

FIG. 14 is a partial side elevational view of a log to be transverselycut into selected lengths before being divided longitudinally inaccordance with this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In this application, smaller logs are considered to be those in therange of 4-9 inches in diameter and 6-10 years in age; larger logs areconsidered to be those in the range of at least 14 inches in diameterand 35 years and up in age.

FIG. 3 shows larger log 30 with horizontal cut lines 32, 34 and verticalcut lines 36, 38 dividing log 30 longitudinally into four three-sidedright-angled equal symmetrical sectors 40. The remaining portions 42, 44of log 30 may be further divided as desired into conventional lumberbeams, planks, etc. Sectors 40 optionally may have one outer edgelongitudinally trimmed off and flattened at 46, as shown, or both suchouter edges on each sector 40 may be flattened if desired. FIG. 4illustrates a finished converted log product 50 made by reorienting thefour three-sided sectors 40 into outer rectangular configuration, withflattened surfaces 46 abutting in each pair of log sectors 40. As shown,the interior space 52 in converted log 50 is substantially and fittinglyfilled with pre-formed foam plastic insulating material 54. Projection56 of insulation 54 extends beyond surface 58 of converted log 50, whilecorresponding and complementary groove 60 is located directly oppositeprojection 56 in opposite face 62 of converted log 50. When convertedlogs 50 are to be assembled at a building site, projection 56 of oneconverted log 50 is mated with groove . .50.!. .Iadd.60 .Iaddend.of theadjacent one, whereby the registering, aligning and interlocking ofconverted logs is aided, whether vertically, as shown, or horizontallyjoined. Centrally disposed opening 64, running the length of convertedlog 50, may be provided advantageously for convenient installation ofelectrical conduits, piping or the like.

In FIG. 5, larger log 70 has its outer portion 72 to be used in theconventional manner by being cut into thin layers while log 70 is beingrotated. The resulting veneers are to be laminated together to produceplywood (this plywood process not shown, being not directly pertinent tothis invention). When log 70 has been reduced by this process to adiameter in the range of 6-71/2 inches, cutting is stopped, andremaining core 74 is conventionally set aside as useless for anythingother than firewood or pulp. However, for this invention, core 74represents an ideal inexpensive raw material source, the wood thereinbeing the densest and strongest of all wood from entire log 70.

By longitudinally bisecting core 74 with cuts along perpendicular planes76, 78, and optionally flattening one or both peripheral edges 80 of thefour log parts 82 formed thereby, the component log parts 82 forconstructing converted log product 84 of FIG. 6 are provided. In thisembodiment, concrete 86, with conventional steel reinforcing bars 88optionally inserted, is shown filling interior space 90 of converted logproduct 84. Concrete 86 and reinforcement 88 may be inserted into 84either at the factory or on location, where the resulting converted logproduct 84 may be advantageously and economically used to replacerailroad ties, in retaining walls and for temporary roads and bridges,to support the weight and resist the stresses of heavy machinery andtrucks passing over them. It may be noted that log parts 82, as well asthe log parts of all preferred embodiments, may be treated withpreservatives, etc. and/or kiln-dried before being assembled intoconverted log products.

The embodiment illustrated in FIG. 7 is converted log product 92 shownin position for assembly but before interior space 94 has been filled.The two log parts 96 shown . .onthe.!. .Iadd.on the .Iaddend.left are ofone species of wood, for example, Douglas fir, while the two log parts98 are of a different species of wood, for example, cedar. In this way,a wall built with converted log products 92 would provide differentinterior and exterior surfaces, taking advantage of the unique qualitiesof grain, hardness, strength and resistance of each species. Manycombinations and designs using various suitable woods are possible usingthis concept.

FIG. 8 illustrates schematically another way to upgrade timber. Lengthof lumber 100 shown therein has been previously cut to a squarecross-section, and may be converted by diagonal longitudinal cuts alongplanes 102 and 104 through the corners of lumber 100 and perpendicularto each other. Two or four of outer corners 106 of lumber 100 may betrimmed off and flattened, as desired, producing right-triangular logparts 108 to be used as shown in FIGS. 9-11. Converted log product 110of FIG. 9 has two corners 106 flattened and is assembled by rotatingparts 108, positioning them to form a peripheral rectangularcross-section. Interior space 112 created by this arrangement isillustratively shown fittingly filled with square-shaped filler piece114 of poor quality wood, such as cottonwood, which is soft, ofinadequate strength and therefore impractical for use by itself asstructural lumber. However, cottonwood, when used as filler 114,combined with and substantially surrounded by strong log parts 108 andoptionally further strengthened and braced as illustrated and describedhereinafter with respect to FIG. 10, is transformed into more thanadequate inexpensive converted log 110, increased in size more than 40%as compared to timber 110 from which it is made.

In FIGS. 10 and 11, converted log product 120 has its log parts 108flattened at all corners 106 and thereby presents a squarecross-sectional configuration. As seen in FIG. 10, cross-braces 116 maybe installed in the assembly of log product 120 and may be spaced alongthe length thereof, while wedge-shaped braces 118, secured to the innercorners where log parts 108 meet, may extend the length of log product120 or optionally be intermittently spaced and secured for increasedstrength and stability of the assembly. FIG. 11 shows interior space 122of log product 120 filled with wood shavings and/or wood chips 124,which may have been treated prior to installation for resistance tofire, fungus, termites and the like, then moistened with adhesive andblown into interior space 122 to impart effective insulative qualitiesto converted log product 120. Other insulative materials, both loose andin the form of fiberglass batts, as well as concrete 86 shown in theembodiment of FIG. 6, may be used in place of wood shavings 124. It maybe noted that log product 120 is increased in overall size almost 40%over timber 100 from which it is made.

The larger log 130 of FIG. 12 is divided by horizontal chordal cut lines132, 134, leaving log portion 136 to be further processed intoconventional lumber by conventional cutting techniques. The remainingtwo log portions are then each split in half by cuts 138 perpendicularto cuts 132, 134. The resulting asymmetric log parts 140 optionally mayhave their outer edges longitudinally trimmed to flattened areas 142. Iflog 130 is large enough in diameter, a second set of log portions 140may be cut therefrom by rotating log 130 90 degrees and repeating cuts132, 134 and 138; remaining portion 136 would then be largely square incross-section (not shown). As seen in FIG. 13, log parts 140 may berearranged in a manner analogous to that of the other embodiments ofthis invention to form converted log 144, which may then be braced andfilled with insulative or strengthening matter as hereinabove describedin connection with other embodiments.

FIG. 14 shows a log 150 to be cut into preselected lengths by transversecuts 152 for use in the practice of this invention.

The converted log products and method of producing them of thisinvention have been described in full detail. Various combinations,substitutions and alternative procedures in the practice of thisinvention are possible without departing from its concepts, spirit orscope, which are defined and limited only by the ensuing claims,wherein:

I claim:
 1. Converted log product, which comprises:four equally sizedparts cut longitudinally from at least one log, said log parts havingbeen cut each to have a three-sided cross-section with two of said threesides being flat and meeting at a right angle, the third of said threesides being selected from the group consisting of: having an arcuatecontour, each of said log parts thereby being a right-angled sector incross-section, and having a flat contour, each of said log parts therebybeing a right triangle in cross-section; . .and.!. .Iadd.support meansfor bracing and strengthening the converted log product, said bracingmeans being positioned at intervals along the length of said log partswithin the interior space formed when said log parts are assembled andsecured; and .Iaddend. means for securing said four equal right-angledlog parts .Iadd.and said bracing support means .Iaddend.together, saidright-angled log parts being positioned when assembled so that saidthird side of each said log part faces inwardly toward each other, saidtwo of said three sides facing outwardly and oriented to form arectangular cross-sectional outline for the assembled converted logproduct.
 2. The converted log product of claim 1, wherein said four logparts are right-angled sectors cut at the periphery of said at least onelog, remaining portions of said log being available for use asconventional lumber.
 3. The converted log product of claim 1, whereinsaid four log parts are right-angled sectors cut from the conventionallydiscarded core of at least one log, the outer portion of said at leastone log having been removed from said core for conventional uses.
 4. Theconverted log product of claim 3, wherein said log core to be cut intosaid sectors may range in diameter from . .4.!. .Iadd.four .Iaddend.toeight inches.
 5. The converted log product of claim 2, wherein said fourright-angled sectors have been cut from said at least one log'speriphery by a first longitudinal chordal cut followed by a secondradial cut at right angles to and bisecting said first chordal cut. 6.The converted log product of claim 1, wherein said four equally sizedlog parts are formed from a log portion previously trimmed to a squarecross-section, said square log portion having been quartered by two ..diagonal.!. corner-to-corner diagonal cuts.Iadd., said cuts having beenmade .Iaddend.perpendicular to each other.
 7. The converted log productof claim 1, wherein each of said four log parts has at least one of itstwo corners connecting said third side with one of said two of threesides trimmed off and flattened to provide a flat surface perpendicularto one of said two of three sides. . .8. The converted log product ofclaim 1, further comprising means for bracing and strengthening theconverted log product, said bracing means being positioned within theinterior space formed when said log parts are assembled andsecured..!.9. The converted log product of claim 1, further comprisinginsulating and strengthening means filling the interior space remainingbetween said four log parts and being secured to said parts, forming aunitary converted log product, said insulating and strengthening meansbeing selected from the group consisting of.Iadd.: .Iaddend.foamplastic, preformed rigid extruded foam plastic conforming in shape andsize to said interior space, loose insulation particles, fiberglassbatts, treated wood shavings, treated wood chips, shaped softwood logs,concrete and reinforced concrete.
 10. The converted log product of claim1, further comprising means for interlocking, aligning and registeringany two converted log products.
 11. The converted log product of claim1, wherein said four log parts may be selected from wood of at least twospecies, whereby different contrasting wood surfaces may face theexterior and interior of a building constructed with converted logproducts so assembled.
 12. The converted log product of claim 6, furthercomprising right-angled wedges secured fittingly in the corners of theinterior space created when said four log parts are assembled, thusbracing and strengthening the converted log product resulting therefrom.13. The method of converting logs into finished dressed structurallumber which comprises the steps of: trimming the logs; cutting logstransversely into selected lengths; cutting log parts therefrom byperpendicular longitudinal cuts so that each log part has a three-sidedcross-section with the first two of the three sides having been cut flatand at right angles to each other, the third side being selected fromthe group consisting of: having an arcuate contour, forming aright-angled sector in cross-section, and having a flat contour, forminga right triangle in cross-section; . .and.!. assembling the lengths of ..the.!. four log parts into position so that the third side of each ofthe four log parts face toward each other, while the flat first twosides thereof face outwardly and are arranged in a rectangularcross-sectional configuration.Iadd.; and inserting into the interiorspace formed in the arranged rectangular configuration, at intervalsbetween and along the length of the four log parts, selectively placedsupport braces.Iaddend..
 4. The method of claim 13, further comprisingat least one step following the longitudinal cutting into three-sidedlog parts and selected from the group consisting of: treating the logparts with preservatives, kiln-drying the log parts and plane-millingthe first two of the three sides of the log parts, in the order herelisted.
 15. The method of claim 13, further comprising the step offilling the interior space, formed when the three-sided log parts havebeen assembled in the arranged rectangular configuration, with means forsecuring the assembled log parts and for strengthening and insulatingthe resultant converted log assembly. . .16. The method of claim 15,further comprising the step of inserting into the interior space andsecuring to the log parts selectively placed support braces, prior tothe step of filling the space with strengthening and insulatingmeans..!.